Electrical power distribution busway having a two-piece housing

Abstract

A low current electrical power distribution busway system which includes a housing composed of two side channels is described. The side channels enclose and secure a plurality of conductive busbars in place. In the preferred form of the invention, the busbars are electrically insulated via an electrostatic spray process. The side channels include a series of corrugations which space the busbars apart at a centerline-to-centerline distance compatible with common bus plugs used with high current busway systems. An S-shaped polychannel mechanically insulates separates the busbars and the side channel corrugations. Each side channel includes a pair of flange members which allow for joining and sealing the busway, and allow for improved structural strength and heat dissipation.

I claim:  
     
       1. An electrical power distribution busway comprising: 
       a plurality of conductive busbars having first and second continuous edges;  
       a busway housing comprising a first and a second electrically conductive side channel joined along joining surfaces of each side channel, each side channel including an inner surface, an outer surface and a plurality of corrugations disposed on the inner surface maintaining the busbars in a spaced-apart, generally parallel relationship;  
       a groove structure formed in at least one joining surface;  
       a sealing material disposed within the groove such that a seal is formed when the side channels are joined; and  
       at least one fastener for connecting the first and second side channels.  
     
     
       2. The busway of claim  1 , wherein the groove structure is disposed on adjacent outer edges of the inner surface of each side channel. 
     
     
       3. The busway of claim  1 , wherein a surface of at least one of the conductive busbars is covered by an electrically insulating material. 
     
     
       4. The busway of claim  3 , wherein the electrically insulated material is deposited by an electrostatic spray process. 
     
     
       5. The busway of claim  1 , wherein the busbars are spaced at a distance of substantially 0.32 inches from centerline to centerline. 
     
     
       6. The busway of claim  1 , further comprising: 
       a single first S-shaped member disposed between the corrugations of the first side channel and the first edges of the busbars; and  
       a single second S-shaped member disposed between the corrugations of the second side channel and the second edges of the busbars.  
     
     
       7. The busway of claim  6 , where each side channel is of a predetermined length and each S-shaped member is of substantially the same predetermined length. 
     
     
       8. The busway of claim  6 , wherein each S-shaped member extends over the corrugation members of each side channel. 
     
     
       9. The busway of claim  6 , wherein each S-shaped member has a tapered profile so that when the busbars are inserted into the S-shaped members, the edges of the busbars are wedged in place. 
     
     
       10. The busway of claim  6 , wherein each S-shaped member is of a tapered profile providing an interference fit among the busbars, S-shaped member and side channels. 
     
     
       11. The busway of claim  6 , wherein the S-shaped members are comprised of extruded plastic. 
     
     
       12. The busway of claim  1 , wherein a single corrugation member is disposed between two adjacent busbars. 
     
     
       13. The busway of claim  1 , wherein each side channel further includes a single semi-circular chamber disposed between two adjacent corrugations. 
     
     
       14. The busway of claim  1 , wherein each side channel has a substantially uniform wall thickness. 
     
     
       15. The busway of claim  1 , wherein each conductive busbar has a substantially rectangular cross-section of a predetermined width and a thickness of substantially 0.094 inches. 
     
     
       16. The busway of claim  15 , wherein the busbars are spaced at a distance of substantially 0.32 inches from centerline to centerline. 
     
     
       17. The busway of claim  1 , wherein each conductive busbar is of predetermined width, each edge is of a first predetermined thickness and a center section of each busbar is of a second predetermined thickness. 
     
     
       18. The busway of claim  17 , wherein the second predetermined thickness is greater than the first predetermined thickness. 
     
     
       19. The busway of claim  17 , wherein the first predetermined thickness is substantially 0.094 inches and the second predetermined thickness is greater than 0.094 inches. 
     
     
       20. The busway of claim  17 , wherein the busbars are spaced at a distance of substantially 0.32 inches from centerline to centerline. 
     
     
       21. The busway of claim  1 , wherein each side channel further comprises a plurality of ribs disposed on the outer surface opposite the corrugations. 
     
     
       22. The busway of claim  1 , wherein each side channel is composed of extruded aluminum. 
     
     
       23. The busway of claim  1 , further comprising a ground busbar, where the ground busbar is supported within the housing and electrically isolated from the busway housing and the other busbars. 
     
     
       24. The busway of claim  1 , wherein each side channel includes an upper flange member and a lower flange member shaped such that the busway housing has an I-beam shape. 
     
     
       25. The busway of claim  24 , wherein at least one of the flange members includes an extension member adapted for clamping a bus plug to the busway. 
     
     
       26. The busway of claim  24 , wherein at least one of the flange members includes a ridge adapted for use in attaching the busway to a structure. 
     
     
       27. An electrical power distribution busway comprising: 
       a plurality of conductive busbars having continuous edges of a first predetermined thickness and a center section of a second predetermined thickness, wherein the second predetermined thickness is greater than the first predetermined thickness;  
       a busway housing comprising a first and a second electrically conductive side channel, each side channel including an inner surface, an outer surface and a plurality of corrugations disposed on the inner surface maintaining the busbars in a spaced-apart, generally parallel relationship, the side channels defining at least one aperture exposing a portion of an edge of a busbar for connection thereto from outside the busway housing; and  
       at least one fastener for connecting the first and second side channels.  
     
     
       28. The busway of claim  27 , wherein the first predetermined thickness is substantially 0.094 inches. 
     
     
       29. The busway of claim  27 , wherein a surface of at least one of the conductive busbars is covered by an electrically insulating material. 
     
     
       30. The busway of claim  29 , wherein the electrically insulated material is deposited by an electrostatic spray process. 
     
     
       31. The busway of claim  27 , wherein the busbars are spaced at a distance of substantially 0.32 inches from centerline to centerline. 
     
     
       32. The busway of claim  27 , further comprising: 
       a single first S-shaped member disposed between the corrugations of the first side channel and the first edges of the busbars; and  
       a single second S-shaped member disposed between the corrugations of the second side channel and the second edges of the busbars.  
     
     
       33. The busway of claim  32 , where each side channel is of a predetermined length and each S-shaped member is of substantially the same predetermined length. 
     
     
       34. The busway of claim  32 , wherein each S-shaped member extends over the corrugation members of each side channel. 
     
     
       35. The busway of claim  32 , wherein each S-shaped member has a tapered profile so that when the busbars are inserted into the S-shaped members, the edges of the busbars are wedged in place. 
     
     
       36. The busway of claim  32 , wherein each S-shaped member is of a tapered profile providing an interference fit among the busbars, S-shaped members and side channels. 
     
     
       37. The busway of claim  32 , wherein the S-shaped members are comprised of extruded plastic. 
     
     
       38. The busway of claim  27 , wherein a single corrugation member is disposed between two adjacent busbars. 
     
     
       39. The busway of claim  27 , wherein each side channel further includes a single semi-circular chamber disposed between two adjacent corrugations. 
     
     
       40. The busway of claim  27 , wherein each side channel has a substantially uniform wall thickness. 
     
     
       41. The busway of claim  27 , wherein each conductive busbar has a substantially rectangular cross-section of a predetermined width and a thickness of substantially 0.094 inches. 
     
     
       42. The busway of claim  27 , wherein the busbars are spaced at a distance of substantially 0.32 inches from centerline to centerline. 
     
     
       43. The busway of claim  27 , wherein each side channel further comprises a plurality of ribs disposed on the outer surface opposite the corrugations. 
     
     
       44. The busway of claim  27 , wherein each side channel is composed of extruded aluminum. 
     
     
       45. The busway of claim  27 , further comprising a ground busbar, where the ground busbar is supported within the housing and electrically isolated from the busway housing and the other busbars. 
     
     
       46. The busway of claim  27 , wherein each side channel includes an upper flange member and a lower flange member shaped such that the busway housing has an I-beam shape. 
     
     
       47. The busway of claim  45 , wherein at least one of the flange members includes an extension member adapted for clamping a bus plug to the busway. 
     
     
       48. The busway of claim  45 , wherein at least one of the flange members includes a ridge adapted for use in attaching the busway to a structure. 
     
     
       49. An electrical power distribution system including a first electrical power distribution busway and a second electrical power distribution busway, the first electrical power distribution busway comprising a first plurality of busbars having edges of a first predetermined thickness, the first plurality of busbars spaced at a first predetermined distance from centerline to centerline, the second electrical power distribution busway comprising a second plurality of busbars having edges of a second predetermined thickness and center sections of a third predetermined thickness, the second plurality of busbars spaced at a second predetermined distance from centerline to centerline; 
       wherein the first predetermined thickness is substantially equal to the second predetermined thickness and the third predetermined thickness is greater than the second predetermined thickness; and  
       wherein the first predetermined distance is substantially equal to the second predetermined distance.  
     
     
       50. The electrical power distribution system of claim  49 , wherein the first predetermined distance and the second predetermined distance are substantially 0.32 inches. 
     
     
       51. The electrical power distribution system of claim  49 , wherein the first predetermined thickness and the second predetermined thickness are substantially 0.094 inches.